Dental casting mold device

ABSTRACT

A dental stone casting mold device (10) for use with a hardenable stone material (21) includes associated first and second side walls (11, 12) first and second end walls (13, 14) and a floor (15), forming an open top cavity (16). Each first and second side walls (11, 12) and first and second end walls (13, 14) extend from the floor (15) in a lateral direction, such that each has a portion (17) proximate to the floor (15) and a portion (18) distal thereto. There is also at least one slot (22) in the floor (15) removably receiving a stone retaining spine (20). In a preferred embodiment, each of first and second side wall (11, 12) carries a plurality of spaced indexing ribs (60). In another embodiment, each distal end 18 of the first and second side walls (11, 12) have integrally associated lateral extensions or webs (80) therefrom. Device (10) may also be provided with indexing bar or articulator attachment structures (101, 110).

This application claims the benefit of U.S. Provisional application Ser.No. 60/038,733 filed Feb. 14, 1997.

TECHNICAL FIELD

The present invention relates to a mold device for use in preparing adental stone cast model. More particularly, the invention relates tosuch a device having a removable retaining spine affixed thereto suchthat dental stone material can be poured into the tray, such that thematerial physically engages and is retained by the retaining spine.Furthermore, the invention relates to such a device having indexing ribswithin the interior of the mold device, a structure for removableaffixing an articulator, and structure for facilitating the removal andreplacement of a cast model into the tray.

BACKGROUND OF THE INVENTION

In the field of dental care, replacement teeth are typically retained inplace by means of bridge work or the like extending from the replacementtooth and anchored to adjacent healthy teeth. The manufacture of suchreplacement teeth and their mechanical bridge structure requires carefulwork to insure proper fitting thereof with respect to adjacent teeth.Also, restoration procedures such as the capping of decayed or brokenteeth likewise requires precise positioning with respect to approximateteeth.

To accurately form and position the replacement tooth or cap, a dentistusually makes a dental go negative or impression of the relevant toothor gap typically including at least the adjacent teeth. This impressionmay be partial, unilateral or bilateral, depending upon the extent ofthe work to be done, and serves as a mold for eventual developing of adie of the patient's tooth to be replaced or restored.

For example, when a tooth is to be crowned or otherwise rebuilt, it isconventional to make a negative, casting or impression of the toothusing a rubber-like impression material. The impression then used as amold for preparing a positive replica of the tooth to be restored. Thereplica is then used to assist in forming a crown model of the toothwhich in turn provides a form or die for making the crown. If needed, afull-bite positive replica of the teeth will be prepared for use ininsuring that the upper and lower teeth sets will be closed togetherproperly.

During preparation of the replica tooth or cap, it is usually necessaryto remove the casting of its precusor or mock-up from the completecasting, often several times. To do this, the casting, such as forexample, a jaw-shaped positive or replica of the gum and upper or lowerteeth set is cut through and a slice of replica gum and teeth setremoved from the set. In this regard, in order to provide a template onwhich to reassemble the pieces of the set, a removable base is typicallyaffixed, such as for example, by casting onto the replica teeth set andgum before it is cut into sections. In order that the individual piecesmay be accurately reassembled in the initial mold, and in accordancewith heretofore conventional practices, each piece is provided with alocating pin or the like which fits into a hole in the base. The pinsare set into the replica pieces during the molding operation.

This technique for preparing the replica such that it can be reassembledin a mold or on a base in proper relation to adjacent teeth in the setrequires that the pins be very accurately positioned in the fluid dentalstone in which the replica tooth or teeth are to be formed. Thisprocedure is difficult because the mold is filled with the moldingmaterial thus obscuring the pins. Further, the outline of the teeth isnot visible from the outside of the mold.

One solution to these drawbacks is described in U.S. Pat. No. 5,306,145.This patent describes a molding device having an open-top cavity forcontaining dental stone material, and a spine removably insertable intothe floor of the cavity. While this device overcame many of theheretofore known drawbacks to modeling devices, a need still exists fora modeling device which will allow very precise control over theplacement of the tooth model into and out of the cavity repeatedly.

Furthermore, a need also exists for a tray with improved set stoneremovable capability, without detrimentally effecting the accuracy ofthe replacement of the stone into the tray. The tray should also becapable of efficiently cooperating with an articulator device.

OBJECTS OF THE INVENTION

It is therefore, an object of the present invention to provide a dentalstone casting mold device.

It is a further object of the present invention to provide a device asabove, that will allow precise indexing of individual sections of astone cast model.

It is another object of the invention to provide a device as aboveconfigured to permit efficient removal of the set stone cast model andaccurate replacement of the model into the device.

It is still an other object of the invention to provide a device asabove configured to cooperatively interact with an articulator device.

These and other objects of the present invention which will becomeapparent from the specification and claims to follow, are carried out bythe invention as hereinafter described and claimed.

SUMMARY OF THE INVENTION

In general, embodiments of the present invention include a dental stonecasting mold device for use with a hardenable stone material. Certain ofthe embodiments comprise associated first and second side wall means,first and second end wall means and floor means forming an open topcavity means. Each of the first and second side wall means and the firstand second end wall means extend from the floor means in a lateraldirection, such that each has a portion proximate to floor means and aportion distal thereto. The inventive device also comprises a slot meansin the floor means for removably receiving a stone retaining spinemeans, and the first and second side wall means are in a spaced andopposing relation to each other.

In certain embodiments, each of the first and second side wall meanscarries a plurality of spaced indexing ribs extending in a directionsubstantially parallel to the lateral direction extension of itsassociated side wall, such that each indexing rib has a lineardimension. At least one indexing rib of the first side wall has a lineardimension greater than the linear dimension of at least one indexing ribof the second side wall.

In another embodiment of the invention, each distal end of the first andsecond side walls have integrally associated lateral extensionstherefrom.

In still another embodiment, each distal end of the first and secondwall means has a linearly extending, raised fracture lip.

In a further embodiment of the invention, the first end wall meanscarries an integrally associated articulator attachment means; such thata pair of the dental stone casting mold devices can be removablypositioned in a parallel, spaced, opposing relation by attachment of thearticulator through the articulator attachment means.

In yet a further embodiment of the invention, the slot means comprisesat least a first slot aperture and a second slot aperture, and the spinemeans comprises at least a first slot retaining portion and a secondslot retaining portion. The first slot retaining portion is removablyreceivable within the first slot aperture, and the second slot retainingportion is receivable within the second slot aperture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a dental modeling trayhaving a spine member received therein, according to the concepts of thepresent invention.

FIG. 2 is a perspective view of one embodiment of the spine member ofFIG. 1.

FIG. 3 is a side elevation and sectional view of the dental modelingtray according to the invention, and taken along lines 3--3 of FIG. 1.

FIG. 4 is a top plan view of the dental modeling tray of FIG. 1, shownwithout the spine member.

FIG. 5 is a side, plan view taken along lines 5--5 of FIG. 4.

FIG. 6 is an end, plan view taken along lines 6--6 of FIG. 5.

FIG. 7 is a side plan view of two dental modeling trays as in FIG. 1,shown for environmental purposes as positioned in a spaced opposingrelationship by an articulator and an indexing bar, and having dentalmodels within each of the modeling trays.

FIG. 8 is a perspective view of an alternative embodiment of a modelingtray according to the present invention.

FIG. 9 is a perspective view of another embodiment of a spine member asin FIG. 8.

FIG. 10 is a side elevation and sectional view of the dental modelingtray according to the invention, and taken along lines 10--10 of FIG. 8.

FIG. 11 is a top plan view of the dental modeling tray of FIG. 8, shownwithout the spine member.

FIG. 12 is a side, plan view taken along lines 12--12 of FIG. 11.

FIG. 13 is an end, plan view taken along lines 13--13 of FIG. 12.

FIG. 14 is an alternative embodiment of the tray in FIG. 11, and is atop plan view.

FIG. 15 is an enlarged view of one portion of the tray in FIG. 14.

PREFERRED EMBODIMENTS OF THE INVENTION

A device for use in the preparation of a dental stone cast or a positivereplica of a patient's teeth, is generally indicated by the number 10 onthe attached drawings. For the sake of this discussion, device 10 willhereinafter be referred to as tray 10. Tray 10 is used in thepreparation of dental models by techniques that are conventional otherthan for those techniques making use of the novel and uniquecharacteristics of tray 10 to be hereinafter described. Suchconventional modeling techniques as were briefly discussed above, aredescribed for example, in U.S. Pat. No. 5,306,145 which is herebyincorporated by reference for such disclosure.

Tray 10 includes associated first and second side wall means 11 and 12respectively, first and second end wall means 13 and 14 respectively,and floor means 15, together cooperating to form an open top cavity 16.As will be more fully discussed below, tray 10 is preferably used incombination with a spine member 20. When affixed to tray 10, spinemember 20 and tray lo cooperate to form a dental modeling device toaccept and removably retain a dental stone modeling material. A dentalstone material model is shown by way of example as material 21 in FIG.7. Each first and second side wall 11 and 12 and first and second endwalls 13 and 14 extend from floor 15 in a lateral direction, such thateach has a portion 17 proximate to floor 15 and a portion 18 distalthereto (FIG. 3).

Tray 10 as depicted in the drawings and as described herein, isrectangular in shape only for the sake of this discussion. It will beappreciated that other shapes including nonlinear portions and the likemay also be useful and which are within the scope of the invention.Thus, a full arch tray 10 or any portion thereof is within the scope ofthe invention.

A preferred embodiment of tray 10 includes a through slot 22 in floor15. Slot 22 is preferably positioned in a central portion of floor 15and extends in a linear direction substantially parallel to sides 11 and12. Spine 20 includes a stone material retaining portion generallydesignated by the number 30 and a slot retaining portion 31 (FIG. 2).

Slot retaining portion 31 includes resilient and opposing retentionmember 32 and 33, configured to be cooperatively and removably receivedwithin and through slot 22, such that the retention member means 32 and33 are deformable when received within slot 22 and resilientlyexpandable after passage through slot 22, to removably retain spine 20and hence, any attached stone material, within tray 10.

Spine 20 is also provided with a flange 34 positioned between slotretaining portion 31 and stone material retaining portion 30, such thatflange 34 limits the distance to which the retention members 32 and 33can be received through slot 22. That is, flange 34 will physicallyengage or be seated upon floor 15. Inner edges 40 and 41 of slot 22 maybe configured to cooperatively, physically engage complementaryindentations 42 and 43 of spine 22 when flange 34 is seated upon floor15.

As shown in FIGS. 10-13, an alternative and preferred embodiment of tray10 includes a groove 44 in floor 15 proximate to or more preferablystraddling slot 22. Flange 34 is received within groove 44 (FIG. 10) andis thereby more precisely positioned within tray 10. Further, slot 22 inanother embodiment, also depicted in FIG. 13, may terminate on anunderside of floor 15, that is the portion of floor 15 facing away fromopen cavity 16, in a guidewall 45. As shown in FIG. 10, guidewall 45 ispreferably positioned on both sides of slot 22, and serves to guideretention members 32 and 33 through slot 22 and to provide a largersurface area (as compared to the embodiment depicted in FIG. 3) forcomplementary inner edges 40 and 41 and indentations 42 and 43. Thisprovides a more secure "lock up" or retention of spine 20 within tray10. As shown in the drawings, retention members 32 and 33 may be taperedto facilitate entry into slot 22 and the deforming thereof.

Stone material retaining portion 30 includes a linearly extending bead50 supported by a neck 51. It will be appreciated that when wet stonematerial is poured into tray 10, in any manner such as by the onedescribed in U.S. Pat. No. 5,306,145, it will flow around bead 50. Whenset, the stone material will be mechanically retained in that positionby physical contact with bead SO and neck S1. That is, bead 50 will beimbedded within set stone material 21. Neck 51 may be of any length andthe length will vary depending upon the desires of the user and therequirements of the particular application. All such lengths are withinthe scope of the invention.

Further, while a preferred configuration of bead 50 is depicted in thedrawings as being bulbous in cross section, any shape is within thescope of the invention. Bead 50 may also be provided with a plurality ofretaining grooves 52 to provide for secure mechanical physicalinteraction with the stone material 21, and to substantially limit oreven prevent lateral movement of stone material 21 hardened about bead50.

Tray 10 is provided with a downwardly extending skirt 53 extendinglaterally from floor 15 in a direction opposite than that of first andsecond side wall means 11 and 12, such that an open bottom cavity 54 isformed opposite that of open top cavity 16. Skirt 53 thereby provides abase for tray 10 and allows room for retention members 32 and 33 toprotrude slot 22 and still allow tray 10 to be placed upon and supportedby a flat surface (not shown).

First and second side walls 11 and 12 are placed in a spaced andopposing relation to each other. Each of the first and second side walls11 preferably carry a plurality of spaced indexing ribs 60. Indexingribs 60 extend in a direction substantially parallel to the lateraldirection extension of its associated side wall 11, 12, such that eachindexing rib 60 has a linear dimension. In the embodiment of theinvention as depicted in the drawings, at least one indexing rib 60 offirst side wall 11 has a linear dimension greater than the lineardimension of at least one indexing rib 60 carried by second side wall12. Thus, when the hardened stone material 21 is removed from tray 10affixed to spine 20, and subsequently cut into individual portions, theportions can be replaced into tray 10 in the exact same location asbefore being removed because the indexing ribs 60 guide the replacement.

Further, by being of different linear dimensions, the individual modelportions cannot be replaced backwards. The ribs 60 will createcomplementary grooves (not shown) in the set stone material and thus,the shorter grooves in the set stone material 21 will not be fullyseatable in a longer rib 60. Other similar configurations, includingalternating dimensions or even ribs all having the same dimension(neither of which are shown) are all within the scope of the invention.

As best shown in FIG. 4, each of the plurality ribs 60 of first sidewall11 are positioned in a staggered opposing relation to the plurality ofindexing ribs 60 of the second side wall 12. That is, each rib 60 of onesidewall 11, 12 does not directly oppose a rib 60 of the oppositesidewall 11, 12, but rather is offset therefrom. This also promotes theproper removal and seating of stone sections into and out of tray 10.Indexing ribs 60 preferably have a portion 70 proximate to floor 15 anda portion 71 distal thereto. Indexing ribs 60 taper outwardly fromdistal portion 70 to proximate portion 71.

Each distal portion 18 of first and second side walls 11 and 12terminate in an integrally formed and associated lateral web 80. Web 80generally defines the top of tray 10, and may have any desired dimensionlateral from walls 11-14. Web 80 serves to provide a handhold for theuser of tray 10 and also to provide a shield against stone material 21from overflowing to the underneath of tray 10. As will be appreciated bythose skilled in the art, removal of stone material from a modeling trayrequires that the stone be disengageable from tray 10. Any mechanicalinteraction between stone material and tray profiles will make thisdifficult. Web 80 helps prevent physical and mechanical interaction withany such profile, and also allows the user to easily clean away anyexcess wet stone material 21.

Further, web 80 can also be positioned to laterally extend from bothfirst and second sidewalls 11, 12, as shown, such that a user can graspweb 80 on either side of tray 10 and exert force thereon to bendsidewalls 11 and 12 away from each other, thereby further facilitatingremoval of stone material 21 from tray 10. Sidewall 11 and 12 proximateportions 17 are closer to each other than are the respective distalportions 18 of opposing sidewalls 11 and 12 (FIG. 3). That is, sidewalls11 and 12 taper upwardly and outwardly toward open top cavity 16, alsopromoting efficient removal and replacement of stone material 21 intoand out of tray 10.

At least one laterally extending web 80 from first or second sidewall 11or 12 has a portion 81 proximate to its associated sidewall 11, 12 and aportion 82 distal thereto. The distal portion 82 may terminate in alinearly extending lip) 83. Lip 83 also facilitates shielding and theuser grasping tray 10 to bend distal portions 18 of sidewalls 11, 12away from each other. To even more fully allow such resilient bending orflexing of tray 10, tray 10 is preferably fabricated from a materialsuch as high density polyethylene or other material to allow flexing.

Distal portions 18 of one or all walls 11-14 may also terminate in alinearly extending, raised fracture lip 84. A knife or other edge (notshown) may be slipped underneath stone material 21 and on top of web 80to engage fracture lip 84. Stone material 21 may thereby be broken fromefficiently removed from tray 10.

In an alternative embodiment of the invention, as is best depicted inFIGS. 8-13, tray 10 is provided with a plurality of slots 22. For sakeof discussion, this slot 22 includes a plurality of slot apertures 90.The embodiment depicted in the drawings has three slot apertures 90,although any number are within the scope of the invention. Spine 20 iscomplementary configured to have a plurality of retaining portionsections 91 (FIG. 9). Each retaining portion section 91 is receivablewithin a complementary slot aperture 90, and is otherwise substantiallysimilar to retaining portion 31 as discussed hereinabove. It ispreferred to arrange a plurality of slot apertures 90 in a juxtaposed,linear relation, as is shown.

Tray 10 may be provided with a vertical stop pin 100 (FIG. 7) affixed toa retaining sleeve 101. In this way, two trays 10 may be affixed in anopposing, spaced relation. Retaining sleeve 101 may be formed by anymeans, such as by fabricating tray 10 with removable plug 102. In use,plug 102 is removed from tray 10 thereby forming open sleeve 101 intowhich stop pin 100 may be inserted. Preferably, stop pin 100 isadhesively bonded at the desired location.

Alternatively, tray 10 may be provided with an articulator attachmentmeans, such as socket 110. Any articulator attachment method andstructure is within the scope of the invention and will vary dependingupon among other things, the articulator design. An example of anarticulator useful with socket 110 is that discussed in U.S. Pat. No.4,548,581 which is hereby incorporated by reference for such disclosure.Articulator 111 has first and second arms 112 and 113 respectively,which each terminate in a ball 114. Each ball 114 is receivable in asocket 110, perhaps positioned by retaining fingers 115, tocooperatively form a ball and socket joint. Articulator arms 112 and 113are hinged at hinge member 116. Two trays 10 may thereby be articulatedrespective to each other to correctly align two stone models 21.

FIGS. 14 and 15 show an alternative embodiment of the tray 10, havingfracture slots or ridges 120. In the embodiment as depicted, fourfracture slots 120 are disposed in a proximate position to the cornersof open top cavity 16. Of course, any number of fracture slots 120 canbe disposed upon tray 10. Fracture slots 120 provide for the material to"break" in the corners during this flexing. This breaking will result inthe four sides 11, 12 13 and 14 being independent of one another duringthe flexing and will provide release of any physical or mechanicalinteraction of the set dental stone and the tray. This independentflexing of the sides provides uniformity of the release, eliminatingdifficulty in flexing the otherwise rigid corners of open top cavity 16.

It will be appreciated that use of tray 10 according to the inventionand as described above, is useful for creating a positive replica of apatient's teeth. Individual sections of the replica can be removed fromthe model and the tray 10 through open top cavity 16, and then beeasily, quickly and precisely returned to its original position. Thetray 10 is particularly suited for a one-pour replicating technique, andprovide accurate indexing without the use of pins. While particularlysuited for dental applications, it will also be appreciated that thetray 10 of the present invention has application to refractory diemaking and the like.

It is apparent therefore, that the modeling device as described abovecarries out and accomplishes the objects of the present invention. Whilethe principles of the embodiments of the invention have been shown inthe drawings and described above, those skilled in the art may makemodifications of structure, arrangement, proportions, elements,materials and components used in the practice of the invention which areparticularly adapted for specific environments and operatingrequirements without departing from those principles, and all of whichare within the scope of the invention.

I claim:
 1. A dental stone casting mold device for use with a hardenablestone material, comprising:associated first and second side wall means,first and second end wall means and floor means forming an open topcavity means; each said first and second side wall means and said firstand second end wall means extending from said floor means in a lateraldirection, such that each has a portion proximate to said floor meansand a portion distal thereto; at least one slot means in said floormeans for removably receiving a stone retaining spine means; said firstand second side wall means being in a spaced and opposing relation toeach other; each of said first and second side wall means carrying aplurality of spaced indexing ribs, said indexing ribs extending in adirection substantially parallel to said lateral direction extension ofits associated side wall, such that each said indexing rib has a lineardimension; at least one indexing rib of said first side wall having asaid linear dimension greater than the said linear dimension of at leastone said indexing rib of said second side wall.
 2. A dental stonecasting mold device as in claim 1, wherein said plurality of indexingribs of said first side wall are placed in a staggered opposing relationto said plurality of indexing ribs of said second side wall.
 3. A dentalstone casting mold device as in claim 1, wherein each said indexing ribhas a portion proximate to said floor means and a portion distalthereto; said ribs tapering outwardly from said distal portion to saidproximate portion.
 4. A dental stone casting mold device as in claim 1,further comprising in combination, a spine means having a slot retainingportion and a stone material retaining portion.
 5. A dental stonecasting mold device as in claim 4, wherein said slot retaining portioncomprises resilient and opposing retention member means configured to becooperatively and removably received within and through said slot means,such that said retention member means are deformable when receivedwithin said slot means, and resiliently expandable after passage throughsaid slot means.
 6. A dental stone casting mold device as in claim 5,further comprising a flange means positioned between said slot retainingportion and said stone material retaining portion, such that said flangemeans limits the distance to which said retention member means can bereceived through said slot means.
 7. A dental stone casting mold deviceas in claim 5, further comprising a downwardly extending skirt extendinglaterally from said floor means in a direction other than that of saidfirst and second side wall means, such that an open bottom cavity meansis formed opposite that of said open top cavity means.
 8. A dental stonecasting mold device as in claim 4, wherein said stone material retainingportion includes a linearly extending bead means, such that the stonematerial is formed around said bead.
 9. A dental stone casting molddevice as in claim 8, wherein said bead is bulbous in cross section. 10.A dental stone casting mold device as in claim 8, wherein said bead isprovided with a plurality of groove means, such that said groove meanssubstantially prevent laterally movement of stone material hardenedabout said bead.
 11. A dental stone casting mold device for use with ahardenable stone material, comprising:associated first and second sidewall means, first and second end wall means and floor means forming anopen top cavity means; each said first and second side wall means andsaid first and second end wall means extending from said floor means ina lateral direction, such that each has a portion proximate to saidfloor means and a portion distal thereto; at least one slot means insaid floor means for removably receiving a stone retaining spine means;said first and second side wall means being in a spaced and opposingrelation to each other; each of said first and second side wall meanscarrying a plurality of spaced indexing ribs, said indexing ribsextending in a direction substantially parallel to said lateraldirection extension of its associated side wall, such that each saidindexing rib has a linear dimension; at least one indexing rib of saidfirst side wall having a said linear dimension greater than the saidlinear dimension of at least one said indexing rib of said second sidewall; each said distal end of said first and second side walls havingintegrally associated lateral extensions therefrom; each said distal endof said first and second wall means having a linearly extending, raisedfracture lip; and, said first end wall means carrying an integrallyassociated articulator attachment means; such that a pair of the dentalstone casting mold devices can be removably positioned in a spaced andopposing relation by attachment of said articulator through saidarticulator attachment means.
 12. A dental stone casting mold device asin claim 11, wherein said plurality of indexing ribs of said first sidewall are placed in a staggered opposing relation to said plurality ofindexing ribs of said second side wall.
 13. A dental stone casting molddevice as in claim 11, wherein each said indexing rib has a portionproximate to said floor means and a portion distal thereto; said ribstapering outwardly from said distal portion to said proximate portion.14. A dental stone casting mold device as in claim 11, furthercomprising in combination, a spine means having a slot retaining portionand a stone material retaining portion.
 15. A dental stone casting molddevice as in claim 14, wherein said slot retaining portion comprisesresilient and opposing retention member means configured to becooperatively and removably received within and through said slot means,such that said retention member means are deformable when receivedwithin said slot means, and resiliently expandable after passage throughsaid slot means.
 16. A dental stone casting mold device as in claim 15,further comprising a flange, means positioned between said slotretaining portion and said stone material retaining portion, such thatsaid flange means limits the distance to which said retention membermeans can be received through said slot means.
 17. A dental stonecasting mold device as in claim 15, further comprising a downwardlyextending skirt extending laterally from said floor means in a directionother than that of said first and second side wall means, such that anopen bottom cavity means is formed opposite that of said open top cavitymeans.
 18. A dental stone casting mold device as in claim 14, whereinsaid stone material retaining portion includes a linearly extending beadmeans, such that the stone material is formed around said bead.
 19. Adental stone casting mold device as in claim 18, wherein said bead isbulbous in cross section.
 20. A dental stone casting mold device as inclaim 18, wherein said bead is provided with a plurality of groovemeans, such that said groove means substantially prevent laterallymovement of stone material hardened about said bead.